Primary and Transmission fluids are both fresh and at proper levels, shaft is freshly greased, clutch is adjusted...

I am not trying to downshift at excessive speeds, and have tried raising the RPM's to unload the trans, all to no avail...

I will try shifting with the linkage disconnected with the bike of the ground.

I'm more concerned with things along the lines of what Lowcountry Joe was saying. I'm starting to worry about a bent fork.

I thoroughly inspected the frame for damage and could not find any.

Def Mute - I have only just heard of adjusting the shift pawl now. I will have to research that further...

Thanks for all the info guys.

 

How many miles since the rebuild? I know i did my salvage bike and it took 500 miles before it was shifting like butter. 2 primary oil changes,2 trans glue changes and a clutch and c able adjustment Its better than most i have riddin

 

I've only ridden about 200 miles since the rebuild. The bike did sit for about a year and a half before I got ahold of it.

Some days seem better than others. At first, I did think it just needed to be ridden some. It didn't seem to consistently getting better so I wasn't sure. I'll put some more miles on it and see what happens.

 

So, I decided to adjust the shifter pawl tonight after I got home from work. I went ahead and pulled the top cover off of the trans so I could see better. When I got the bike into 3rd, the pawl was all the way forward with 0 gap at the rear... As I try to adjust it, there just simply isn't enough movement to get the dowels centered in the pawl. I can get a TINY gap in the rear, but nowhere near center.

Now I'm lost, what could cause this?!?

 

The eccentric on the end of the adjusting nut can wear, but I don't think it would wear that much unless it broke off completely. Maybe pull the adjusting bolt out and look at the eccentric on the end. Also, have a good look at the shift pawl spring. They break sometimes.

Put your hand around the shift drum as much as you can, and see if you can push it sideways on the shaft that it turns on. Maybe a bad bearing in the shift drum...